Lens arrays and mountings

ABSTRACT

A light-emitting diode module includes a printed circuit board with a light-emitting diode array mounted on first surface. A secondary lens array is positioned over the light-emitting diode array and includes a secondary lens element for each light-emitting diode element in the light-emitting diode array. A lens holder is mounted to the printed circuit board and configured to retain each secondary lens element of the secondary lens array in alignment in an x-y plane with respect to each light-emitting diode element of the light-emitting diode array. The printed circuit board further includes a first locating feature corresponding to a second locating feature of either the secondary lens array or the lens holder. The locating features align the secondary lens array with respect to the light-emitting diode array on the printed circuit board.

CROSS-REFERENCE TO RELATED APPLICATION(S

This application is a continuation of U.S. application Ser. No.14/975,069, filed Dec. 18, 2015, which is based on EP 15152505.2, filedJan. 26, 2015, the disclosures of which are hereby expresslyincorporated by reference herein in their entirety.

FIELD OF THE INVENTION

The present invention relates to improvements in or relating to lensarrays, and is more particularly concerned with the mounting of suchlens arrays with respect to light-emitting diode elements mounted on aprinted circuit board.

BACKGROUND

Light emitting diode (LED) based luminaires often comprise modulesincluding printed circuit boards (PCBs) on which the LEDs are mounted.The LEDs are typically arranged in an array or pattern and mounted onthe PCB, often termed PCB assembly (PCBA), which is appropriate for theluminaire in which they are to be used. Whilst each LED comprises alight source with a primary optical element or lens, secondary opticalelements are often required to direct the light produced by these lightsources in directions appropriate to the particular implementation in aluminaire. Lenses are typically used as the secondary optical elementsfor directing the light.

In current applications, most secondary lenses are made out of ratherrigid materials, such as polymethylmethacrylate (PMMA) or polycarbonate,and are mounted on the PCBA by the use of screws or rivets which provideprecise positioning of the secondary lenses with respect to theassociated LEDs.

Unfortunately, the use of PMMA or polycarbonate lenses as secondarylenses tends to limit the operating temperature of the PCBA.Conventional plastic materials such as PMMA and polycarbonate cannot beexposed to temperatures exceeding 85° C. without long termdeterioration, for example, due to thermo-oxidation. The LEDs and PCBAs,particularly when they comprise metal core PCBs (MCPCBs), are moreresistant to higher temperatures, and, the material from which thesecondary lenses are most often made limits the maximum operabletemperature of the assembly. This limitation in temperature necessitatesthe provision of good dissipation techniques on the luminaire to keepthe temperatures under this limit. This requires costly heat dissipatingstructures, for example, heat sinks which increase the amount of metal,for example, aluminium, required in the manufacture of the luminairehousing or body in which the LEDs are mounted.

Silicone is now being implemented in more and more applications assecondary lenses for use with PBCAs as it can operate at highertemperatures than PMMA and polycarbonate without significant degradationof the material, whilst providing optical properties that remainconsistent over extended periods of time. Silicone is a proven materialfor use in encapsulated LED primary lenses due to its ability to operateat higher temperatures.

However, when implementing silicone as a single moulded lens array, itbecomes difficult to mount the array precisely on the PCBA and tomaintain precise alignment between the secondary lenses and the LEDs.This is due to silicone itself being a soft material and the mouldedlens array is flexible. More particularly, due to the relative softnessand flexibility of the material, it is no longer possible to useconventional mounting techniques, for example, using screws, rivets,etc.

Furthermore, the goal of achieving higher operating temperaturesgenerates even more severe constraints due to different thermalcharacteristics of the materials from which the secondary lenses andPCBA are made. These characteristics need to be taken into account toprovide a reliable mounting of the lenses whilst also maintainingcorrect lens alignment with respect to the LEDs during temperaturechanges.

SUMMARY

It is therefore an object of the present invention to provide a methodof providing precise alignment between a moulded secondary lens arraymade of a soft, flexible material and an array of LED elements mountedon a printed circuit board.

It is another object of the present invention to provide a method ofattaching a moulded secondary lens array to a printed circuit boardwhich provides precision of mounting in three-dimensions.

It is a further object of the present invention to provide means forattaching a moulded secondary lens array with precision which does notrequire any tools.

It is yet another object of the present invention to provide means forcompensating for different thermal characteristics of the components inan LED module.

In accordance with one aspect of the present invention, there isprovided a light-emitting diode module comprising:—

a printed circuit board having a first surface and a second surface;

a light-emitting diode array mounted on first surface of the printedcircuit board, the printed circuit board providing electricalconnections to each light-emitting diode element in the light-emittingdiode array; and

a secondary lens array operable for being positioned over thelight-emitting diode array, the secondary lens array including asecondary lens element for each light-emitting diode element in thelight-emitting diode array;

characterised in that the module further comprises a lens holdermountable to the printed circuit board and operable for retaining eachsecondary lens element of the secondary lens array in alignment in anx-y plane with respect to each light-emitting diode element of thelight-emitting diode array and for maintaining the secondary lens arrayat a predetermined distance, in a direction perpendicular to the x-yplane, from the first surface of the printed circuit board;

and in that the printed circuit board comprises locating meanscorresponding to one of: locating means of the secondary lens array andlocating means of the lens holder for providing the alignment of thesecondary lens array with respect to the light-emitting diode array onthe printed circuit board.

By providing the alignment in the x-y plane, and, also in the directionperpendicular to the x-y plane, it is possible to retain the secondarylens elements in a fixed relationship with respect to the printedcircuit board and the light-emitting diode elements formed thereon. Inaddition, there is no possibility of any deformation of the secondarylens array which would create spaces between the array and thelight-emitting diode elements on the printed circuit board.

In addition, correct x-y positioning of the secondary lens elements onthe printed circuit board is maintained throughout the operatingtemperature range of the light-emitting diode module.

The locating means of the printed circuit board comprises at least oneaperture formed therethrough and the locating means of the lens holdercomprises at least one clip formed on a surface thereof, each clip beingoperable for engaging an associated aperture when the module isassembled.

In one embodiment, the secondary lens array comprises a free form lensarray having a first surface and a second surface located on oppositesides thereof, the secondary lens elements being formed as a convexsurface in the first surface and as a concave surface in the secondsurface respectively of the free form lens array.

The lens holder may comprise a frame operable to secure the free formlens array to the printed circuit board, the frame having a firstsurface and a second surface which are located on opposite sides thereofwith apertures formed therethrough for receiving respective ones of thesecondary lens elements.

The frame may preferably include at least one hole for receiving atleast one pin formed in the first surface of the free form lens array,the first surface of the free form lens array being aligned with asecond surface of the lens holder so that each pin extends through anassociated hole.

In this embodiment, the secondary lens array is positioned between thefirst surface of the printed circuit board and the second surface of thelens holder. The second surface of the free form lens array may furthercomprise at least one positioning pin for engaging a correspondingrecess formed in the printed circuit board. In one embodiment, there aretwo positioning pins, each one having a different cross-section.

By using such a lens holder, no excessive pressure is applied to thefree form lens array which could generate any optical distortion of thesecondary lens elements.

In another embodiment, the lens holder may further comprise an elementfor each secondary lens element of the secondary lens array formed inthe first surface of the lens array in the proximity of an associatedaperture to prevent backlighting.

In a further embodiment, the secondary lens array comprises a collimatorlens array including a plurality of collimator lens elements.

In this embodiment, the lens holder may comprise a frame operable tomount the collimator lens array to the printed circuit board, the framehaving a first surface and a second surface which are located onopposite sides thereof, the first surface having a plurality forrecesses defined therein, each recess corresponding to a light-emittingdiode of the light-emitting diode array and being operable to receive anassociated collimator lens element.

In this embodiment, the lens holder includes at least one positioningpin located on its second surface for engaging a corresponding apertureformed at least in the first surface of the printed circuit board. In apreferred implementation of this embodiment, the lens holder includestwo positioning pins each having a cross-section and the first surfaceof the printed circuit board has two apertures each being shaped toreceive a corresponding positioning pin.

The lens holder may further comprise at least one clip formed in an edgeportion of each recess, each clip being operable to retain a collimatorlens element in the associated recess.

By providing a lens holder with recesses for receiving the collimatorlens elements and using the clips at the edges of the recesses, noexcessive pressure is applied to the material from which the collimatorlens elements are made which could generate any optical distortion ofthe lens elements.

In accordance with the present invention, each secondary lens arraypreferably comprises an optical grade silicone material and thesecondary lens array is moulded as a single component.

In accordance with another aspect of the present invention, there isprovided a luminaire having a light-emitting diode module as describedabove.

In accordance with a further aspect of the present invention, there isprovided a method of assembling a light-emitting diode module comprisinga printed circuit board having a first surface and a second surface, alight-emitting diode array mounted on first surface of the printedcircuit board, a secondary lens array, and a lens holder having a firstsurface and a second surface, the method comprising:—

providing locating means on the first surface of the printed circuitboard;

providing locating means on one of: the second surface of the secondarylens array and the second surface of the lens holder;

forming a lens array assembly by assembling the secondary lens array inthe lens holder; and

mounting the lens array assembly on the first surface of the printedcircuit board;

characterised in that the locating means on the first surface of theprinted circuit board cooperates with the locating means on one of: thesecond surface of the secondary lens array and the second surface of thelens holder to align the secondary lens array with the light-emittingdiode array in an x-y plane and to maintain the secondary lens array ata predetermined distance, in a direction perpendicular to the x-y plane,from the first surface of the printed circuit board.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same become betterunderstood by reference to the following detailed description, whentaken in conjunction with the accompanying drawings, wherein:

FIG. 1A illustrates a perspective view of a free from lens array to bemounted on a printed circuit board;

FIG. 1B illustrates a perspective view of a collimator lens array to bemounted on a printed circuit board;

FIG. 2 illustrates a perspective exploded view of a first embodiment ofa lens array assembly comprising the free form lens array of FIG. 1A;

FIG. 3 illustrates a perspective view of the lens array assembly of FIG.2 but viewed from underneath;

FIG. 4 illustrates a perspective view of the lens holder of FIGS. 2 and3 when viewed from underneath;

FIG. 5 illustrates a perspective view of the lens array assembly of FIG.3 but viewed from the top;

FIG. 6 illustrates an exploded perspective view of one embodiment of anLED module in accordance with the present invention;

FIG. 7 illustrates a perspective view of another embodiment of a lensholder for use with a free form lens array;

FIG. 8 illustrates an exploded perspective view of a collimator lensarray assembly;

FIG. 9 illustrates a perspective view of the collimator lens arrayassembly of FIG. 8 when viewed from the top; and

FIG. 10 illustrates a perspective view of the collimator lens arrayassembly of FIGS. 8 and 9 when viewed from underneath.

DETAILED DESCRIPTION

The present invention will be described with respect to particularembodiments and with reference to certain drawings but the invention isnot limited thereto. The drawings described are only schematic and arenon-limiting. In the drawings, the size of some of the elements may beexaggerated and not drawn on scale for illustrative purposes.

Throughout the following description, identical components bear the samereference numerals.

Although the present invention will be described with reference to LEDmodules suitable for luminaires, it will readily be appreciated that theinvention is not limited to such an implementation and can be used inany LED module, particularly if it requires use at higher temperatures.

The term “higher temperatures” as used herein refers to temperatures inexcess of 85° C., and can refer to temperatures as high as 150° C.

The term “silicone material” as used herein refers to an optical gradesilicone material having a Shore 00 hardness value in the range ofbetween 60 and 100. As will readily be understood, these values rangefrom soft to medium hard and will affect the pliability, flexibility anddurability of lens arrays made from such materials.

The term “light-emitting light diode module” or “LED module” as usedherein refers to an assembly of a PCB on which are mounted an array ofLED elements, a secondary lens array and a lens holder for mounting thesecondary lens array on the PCB. It is essential that each element ofthe secondary lens array is correctly aligned with an associated LEDelement in the LED array formed on the PCB.

The term “free form lens array” as used herein refers to a lens arraywhich the lens elements are designed as light beam shapers to create apredetermined light distribution and which are positioned overassociated LED elements of an LED array. Free form lens arrays aretypically used as secondary lenses in luminaires for street lightingapplications. In accordance with the present invention, the free formlens array is moulded as a single component from an optical gradesilicone material.

The term “collimator lens array” as used herein refers to a lens arrayin which the lens elements comprise beam collimators. Collimator lensarrays are used to deliver focussed beams of light and may be used assecondary lenses in luminaires for specialised projectors inillumination or sport lighting applications or other more specificlighting applications. The collimator lens array is moulded as a singlecomponent from an optical grade silicone material.

The term “lens array” as used herein refers to an arrangement or patternof at least one lens element. In the embodiments described below, eachlens array comprises eight lens elements which are integrally formed asa single component. It will, however, be appreciated a lens array maycomprise any number of lens elements which may either be integrallyformed as described below, or separately formed and arranged to form thelens array.

Silicone lenses used as secondary lenses may have different sizes andstructures depending on their optical properties, and enable operationof lighting devices incorporating such lenses at higher temperatureranges. This means that it is possible to either increase the operatingtemperature range whilst using conventional heat sinks for heatdissipation or to reduce the amount of heat sinks required for heatdissipation without adversely affecting the operation of the luminaire.Naturally, by reducing the amount of material needed for heatdissipation, cost benefits can be provided.

It will readily be appreciated that the optical properties of thesilicone lenses needs to be maintained over the full operatingtemperature and not show any degradation over time when operating athigher temperatures.

FIGS. 1A and 1B illustrate two examples of secondary lenses integrallyformed as one component using injection moulding techniques.

FIG. 1A illustrates an exploded view of a free form lens array assembly100. The assembly 100 comprises a PCB 110 on which are mounted sixteenLED elements 120 arranged as two groups 120A, 120B of eight elements.The PCB 110 also includes mounting holes 150, 160 to which a free formlens array 210 is mounted as will be described in more detail below.Mounting holes 170 are also provided in the PCB 110 for mounting theassembly 100 to a luminaire housing (not shown), and positioningapertures or holes 180, 190 are provided for the correct alignment of alens array assembly as will be described in more detail below.

The assembly 100 also comprises a free form lens array 210 is which canbe mounted over either group 120A or group 120B of LED elements 120. Thefree form lens array 210 comprises eight secondary lens elements 220,arranged in a two-by-four configuration, joined together by a skirtportion 230 which surrounds each of the secondary lens elements 220.Each secondary lens element 220 comprises a convex portion 220A (shownmore clearly in FIG. 2) formed as part of a first surface and a concaveportion 220B (shown in FIG. 3) formed as part of a second surfacerespectively of the free form lens array 210. Naturally, a second freeform lens array (not shown) may be provided for the other group of LEDelements 120.

It will readily be appreciated that the free form lens array 210 is notlimited to eight secondary lens elements 220 and may comprise anysuitable number of secondary lens elements in accordance with theparticular lighting application in which the free form lens array 210 isto be used. Moreover, the alignment and/or orientation of the secondarylens elements 220 within the free form lens array 210 is not limited tothe alignment and orientation shown in FIG. 1A and described herein andmay be any other suitable alignment and/or orientation in accordancewith the particular lighting application.

An alignment pin 240 is formed in the skirt portion 230 of the free formlens array 210 which aligns with a corresponding aperture or hole in alens holder as will be described in more detail below. Other markings(not shown in detail) may be present on the skirt portion 230 which areintended to provide correct alignment with respect to the PCB 110 andthe LED elements 120 of an LED array formed thereon.

FIG. 1B illustrates an exploded view of a collimator lens array assembly300. The collimator lens assembly comprises PCB 110, described abovewith reference to FIG. 1A, and one collimator lens array 310 which canbe mounted over either group 120A or group 120B. The collimator lensarray 310 comprises eight secondary lens elements 320, arranged in atwo-by-four configuration, joined together by an elongate strip 250extending down the centre of the collimator lens array 310. Again, asecond collimator lens array (not shown) may be provided over the othergroup of LED elements 120.

It will readily be appreciated that the collimator lens array 310 is notlimited to eight secondary lens elements 320 and may comprise anysuitable number of lens elements in accordance with the particularlighting application in which the collimator lens array 310 is to beused. Moreover, the alignment of the secondary lens elements 320 withinthe collimator lens array 310 is not limited to the alignment shown inFIG. 1B and described herein and may be any other suitable alignment inaccordance with the particular lighting application.

As described above, in both the embodiments shown in FIGS. 1A and 1B, itis essential that there is correct alignment of the secondary lenseswith respect to the LED elements in the LED array, and hence, an x-yplane defined by the surface of the PCB, and that that alignment ismaintained through the full operating temperature range of the LEDmodule of which the secondary lenses form a part.

In addition, it is essential that there is no deformation of thesecondary lens array in a direction perpendicular to the x-y plane thatwould create any space between the secondary lens array and the LEDarray on the PCB due to the soft, flexible material of the siliconelenses without creating excess pressure that could generate opticaldistortions in the secondary lens array.

Moreover, in addition to the requirements described, the assembly of thesecondary lenses on the PCBs needs to be easy and straightforward in anindustrial environment.

In accordance with the present invention, a lens holder is provided formounting the secondary lens array with respect to the PCB. In oneembodiment, the lens holder comprises a simple frame to surround andretain the secondary lens elements, and, in another embodiment, the lensholder comprises a shaped structure to support the secondary lens arrayas will be described in more detail below.

Referring now to FIG. 2, an exploded view of a first embodiment of alens array assembly 400 is shown. The lens array assembly 400 comprisesthe free form lens array 210 shown in FIG. 1A and a lens holder 410. Thelens holder 410 comprises a frame having eight apertures 420 shaped toreceive a respective one of the secondary lens elements 220 whenassembled. The lens holder 410 has a first surface and a second surface,the second surface being in contact with the first surface of the freeform lens array 210 when assembled, that is, the lens holder 410 ispositioned over the free form lens array 210 and is not in contact withthe PCB 110. The second surface of the free form lens array 210 is incontact with the PCB 110 when an LED module (as shown in FIG. 6) isassembled. It will be appreciated that, although not shown, the concaveportion 220B of each secondary lens element 220 is placed nearer to theLED element which it is associated than the convex portion 220A.

The frame includes an aperture or hole 440 with which the alignment pin240 of the skirt portion 230 of the free form lens array 210 engageswhen assembled. This ensures correct alignment of the free form lensarray 210 with the lens holder 410 so that the secondary lens elements220 are located within apertures 420 of the lens holder 410, with theirconvex portions 220A above the frame, when the lens holder 410 isassembled with the free form lens array 210.

Clips 450, 460 are provided as part of the lens holder 410 for aligningwith corresponding apertures or holes 250, 260 formed in the skirtportion 230 of the free form lens array 210 as shown. As shown, theapertures or holes 250, 260 may comprise elongate slots, but theapertures or holes 250, 260 are not limited to such a configuration.

The clips 450, 460 extend through the apertures or holes 250, 260 whenthe frame 410 is assembled with the free form lens array 210 as will bedescribed in more detail below. The clips 450, 460 are moulded from thesame material as the frame and are integrally formed therewith.

When an LED module is assembled, as will be described in more detailbelow, the clips 450, 460 extend through into corresponding holes 150,160 formed in the PCB 110.

Markings 470, 475 on the first surface of the frame 410 are aligned withcorresponding markings 270, 275 provided on the first surface of thefree form lens array 210, and in particular, on the skirt portion 230thereof.

FIG. 3 illustrates the lens array assembly 400 from underneath, that is,from the second surface of the free form lens array 210. As shown, thefirst surface of the free form lens array 210 is in contact with thesecond surface of the lens holder array 410. Positioning pins 280, 290are provided on the second surface of the free form lens array 210 whichengage with corresponding apertures or holes 180, 190 provided in thePCB 110 (as described above with reference to FIG. 1A).

The positioning pins 280, 290 are shaped to allow for thermal expansionof an assembled LED module (not shown) without creating any deformationin the free form lens array 210. In one embodiment as shown, one pin 290has a circular cross-section and the other pin 280 has a rhomboid(lozenge) cross-section. However, it will be appreciated that othercross-sections are possible for the positioning pins 280, 290 as long asthey can accommodate dimensional changes due to thermal expansion.

The positioning pins 280, 290 provide correct referencing of the freeform lens array 210 with respect to the PCB 110 when inserted intocorresponding apertures 180, 190 in the PCB 110. This reference ismaintained between the free form lens array 210 and the PCB 110 with thelens holder 410 being prevented from putting any mechanical constrainton this positioning. In effect, the lens holder 410 is only used tomaintain the second surface of the free form lens array 210 in contactwith the first surface of the PCB 110.

As described above with reference to FIG. 2, the lens holder 410incorporates clips 450, 460 which provide a simple and rigid mounting ofthe lens holder 410 to both the free form lens array 210 and the PCB110. The positioning of these clips 450, 460 and their flexibility iscrucial to maintain the lens holder 410 properly aligned with respect tothe free form lens array 210 and to the PCB 110 whilst adjusting forthermal expansion.

FIG. 4 illustrates a perspective view of the lens holder 410 fromunderneath so that the location of the clips 450, 460 and the apertureor hole 440 can clearly be seen. As described above, the clips 450, 460are flexible and are designed to have sufficient flexibility to adjustwith differences in thermal expansion between the material from whichthe PCB 110 is made and the material from which the lens holder 410 ismade. Non-limiting examples of materials from which the lens holder 410may be made include thermoplastic materials, for example, polycarbonate(PC), polyphenylene sulphide (PPS), polybutylene terephthalate (PBT) andpolyamide (PA).

FIG. 5 illustrates a top perspective view of the lens array assembly400. As shown, the markings 470, 475 and the aperture or hole 440 formedon or in the lens holder 410 are used to ensure that there is correctorientation with the free form lens array 210. As described above,markings 470, 475 are matched to corresponding markings 270, 275 on thefree form lens array 210 as shown in FIG. 2. The aperture or hole 440 issized to accommodate the positioning pin 240 formed on the skirt portion230 of the free form lens array 210, and is used as a “foolproof”mounting mechanism.

The provision of the markings 270, 275 and pin 240 on the free form lensarray 210 and the markings 470, 475 and aperture or hole 440 on the lensholder 410 ensures that lens holder 410 is correctly oriented with thefree form lens array 210 when being assembled. It will readily beappreciated that other methods of ensuring that the free form lens array210 is correctly oriented with respect to the lens holder 410 arepossible, for example, shaped protrusions may be formed on the lensholder which engage corresponding depressions or apertures formed in theskirt portion 230 of the free form lens array 210.

Once the lens array assembly 400 has been assembled, the clips 450, 460integrally formed with the frame of the lens holder 410 extend throughcorrespond holes 250, 260 formed in the free form lens array 210 (shownin FIG. 2), and, when mounted on the PCB 110, the clips 450, 460 extendthrough corresponding holes 150, 160 (shown in FIG. 1A) to complete afirst embodiment of an LED module.

FIG. 6 illustrates an exploded view of such an LED module 500 comprisingthe PCB 110 and the lens array assembly 400 which comprises the freeform lens array 210 and the lens holder 410 as described above. Asshown, the apertures or holes 250, 260 formed in the free form lensarray 210 may comprise elongate slots to allow for differences intolerances when the free form lens array 210 is moulded. These elongateslots also provide compensation for any tolerances in the moulding ofthe lens holder 410.

In addition, the LED module 500 may include a second lens array assemblywhich is located alongside the lens array assembly 400 so that bothgroups 120A, 120B of eight LED elements 120 (FIGS. 1A and 1B) on the PCB110 are associated with secondary lens elements.

Alternatively, for PCB 110 having sixteen secondary lens elements 120,the lens array assembly may comprise twice the size of the lens arrayassembly 400 and is capable of being mounted over all of the sixteensecondary lens elements 120. In this case, the lens holder may comprisefour clips instead of two to provide the desired mounting. Moreover, thelens array assembly may comprise one free form lens array having therequisite number of secondary lens elements and two lens holders 410 maybe employed to mount the single free form lens array. Similarly, twofree form lens arrays may be mounted using a single lens holder.

It will readily be understood that the LED module 500 can easily beassembled in seconds without the need for any tools, the clips 450, 460providing the engagement necessary to retain the components of the LEDmodule together.

An another embodiment of a lens holder 610 is shown in FIG. 7. Lensholder 610 comprises a frame having eight apertures 620 shaped toreceive a respective one of the lens elements 220 of the free form lensarray 210 shown in FIG. 2 when assembled. The lens holder 610 has afirst surface and a second surface, the second surface being in contactwith a first surface of the free form lens array 210 when assembled inan identical way to that of the lens holder 410 described above withreference to FIGS. 2 to 6.

The frame includes an aperture or hole (not shown) with which thealignment pin 240 of the skirt portion 230 of the free form lens array210 engages when assembled. This ensures correct orientation of the freeform lens array 210 with the lens holder 610 so that the lens elements220 are located within apertures 620 of the lens holder 610 when thelens holder 610 is assembled with the free form lens array 210.

Clips 650, 660 are provided for engaging corresponding holes 250, 260formed in the skirt portion 230 of the free form lens array 210 asdescribed above. The clips 650, 660 extend through the holes 650, 660when the frame 610 is assembled with the free form lens array 610.

Markings 670, 675 on the first surface of the frame 610 are aligned withcorresponding markings 270, 275 provided on the first surface of thefree form lens array 210, and in particular, on the skirt portion 230thereof. As described above with reference to FIGS. 2 and 3, secondarylens elements 220 of the free form lens array 210 extend throughapertures 620 in the frame so that the convex portion 220A of eachsecondary lens element is above the frame of the lens holder 610.

The lens holder 610 further comprises eight louvre elements 695 whichare used to prevent backlighting from a luminaire in which an LED moduleincluding such a lens holder 610 is mounted. This is advantageous toprevent unwanted illumination of house façades in a residentialenvironment.

The material of the lens holder 610 may be made from a light absorptiveor reflective material depending on the particular properties requiredfor the louvre elements 695. Alternatively, the lens holder 610 may bemade from the same materials as the lens holder 410 but with a suitablecoating to modify the light absorption or reflective properties thereof.In one embodiment, only one surface of a louvre element may be coated,that is, the surface which is nearer to the secondary lens element 220.

As described above, the lens holder 610 may be of any suitable size inaccordance with the particular application of the LED module (not shown)in which it is implemented.

As an alternative to the embodiment of the free form lens array 210described above with reference to FIGS. 2 to 7, it is possible to mounteach secondary lens element separately on the PCB 110. In this case,each lens element has its own positioning pins which engage withcorresponding positioning pins on the PCB 110. Whilst it is possible tomount the secondary lens elements separately, this requires more workduring assembly to ensure that there is correct alignment with respectto associated LED elements.

Referring now to FIG. 8, an exploded view of another embodiment of alens array assembly 700 is shown. The lens array assembly 700 comprisesa collimator lens array 310 as described with reference to FIG. 1B and alens holder 710. In this embodiment, the lens holder 710 is positionedbetween the collimator lens array 310 and the PCB 110 when an LED module(not shown) including such a collimator lens array is assembled. Thelens holder 710 comprises a frame having first and second surfaces asdescribed above with reference to lens holder 410 (FIGS. 2 to 6) andlens holder 610 (FIG. 7).

On the first surface, eight recesses 720 are formed to receiverespective ones of the eight secondary lens elements 320 in thecollimator lens array 310. The recesses 720 are formed by shaped wallelements 725 extending from the frame and which are arranged, in pairsas shown, to define the recesses. In the illustrated embodiment, eachwall element 725 comprises two concave portions 725A, 725B, and, pairsof wall elements 725 are arranged to oppose one another with pairs ofconcave portions in defining the recesses 720. Each concave portion725A, 725B includes a clip 725C which cooperates with a clip of anopposed concave portion to engage a secondary lens element 320 of thecollimator lens array 310 as will be described in more detail below.

Each recess 720 has a proximal end 720A and a distal end 720B, theproximal end 720A being located adjacent the frame and the distal end720B being spaced from the frame. In this particular embodiment, thedistance between the proximal end 720A and the distal end 720B of arecess is substantially the same as the height of each secondary lenselement 320 of the collimator lens array 310.

At the proximal end 720A of each recess 720, a circular aperture 720C isprovided in the frame so that the frame can be positioned on the PCB 110(FIG. 1B) with the LED elements 120 mounted on the PCB 110 being alignedwith the circular apertures 720C.

As shown, each secondary lens element 320 of the collimator lens array310 is substantially conical with a proximal end 320A and a distal end320B, the distal end 320B having a larger cross section than theproximal end 320A. When the collimator lens array 310 is assembledwithin the lens holder 710, the proximal end 320A and the distal end320B of each secondary lens element 320 is respectively aligned with theproximal end 720A and the distal end 720B of each recess 720. Theproximal end 320A of each secondary lens element 320 is centred withinthe recess 720 with respect to the circular aperture 720C associatedtherewith, and, the distal end 320C is retained in position within therecess 720 by clips 725C of the opposing concave portions of the twowall elements 725 defining the recess 720. This will be described inmore detail below with reference to FIGS. 9 and 10.

FIG. 9 illustrates a perspective view of the lens array assembly 700. Asshown, each secondary lens element 320 is retained within one recess 720with the proximal portion 320A being located in the circular aperture720C and the clips 725C of the wall elements 725 surrounding a portionof the distal end 320B of the secondary lens element 320.

On the second surface of the lens holder 710, clips 750, 760 areprovided which correspond to the clips 450, 460 of the lens holder 410and the clips 650, 660 of the lens holder 610. In this embodiment, theclips 750, 760 do not extend through the collimator lens array 310 whenthe collimator lens array 310 is assembled in the lens holder 710.

Alignment pins 780, 790 are provided for engaging respective aperturesor holes 180, 190 in the PCB 110. In this case, the alignment pins 780,790 take the place of the positioning pins 280, 290 of the free formlens array 210 (FIG. 3) to ensure that there is alignment of the lensholder 710 with respect to the LED elements 120 on the PCB 110.

Correct positioning of the lens array assembly 700 with respect to theLED elements 120 on the PCB 110 is guaranteed by the two positioningpins 780, 790 located on the lens holder 710. As described above withreference to FIG. 3, the positioning pins may have the same or differentcross-sections to allow for changes due to thermal expansion of anassembled LED module (not shown) without creating deformation in thecollimator lens array 310 or the lens holder 710. In the describedembodiment, positioning pin 780 has a rhomboid (lozenge) cross section,and, positioning pin 790 has a circular cross-section. As describedabove, any cross-section combination is possible as long as thepositioning pin can accommodate thermal expansion.

Although a wall element of a particular shaped is described withreference to FIGS. 8 to 10 for the lens holder 710, it will readily beappreciated that other differently shaped wall elements are alsopossible to provide support for the collimator lens array 310. Inaddition, the collimator lens array 310 may comprise secondary lenselements 320 which are arranged in a different format within the arrayand connected together in a different manner.

In accordance with the present invention, the free form lens array andthe collimator lens array are moulded in a single process so that thesecondary lens elements are connected to one another to provide easy ofhandling during assembly of the lens arrays and then the final LEDmodule.

The embodiments described above with reference to FIGS. 2 to 7 (freeform lens array 210) and FIGS. 8 to 10 (collimator lens array 310)provide accurate positioning of flexible lenses over LED elements on aPCB with the advantages of:

-   -   a) easy mounting in an industrial environment without the need        for tools;    -   b) no requirement for adhesives to fix the silicone lens arrays        in place over the LED array on the PCB;    -   c) no requirement for screws or other fixings which penetrate        the silicone lens arrays; and    -   d) the LED modules can operate at higher temperatures without        having optical distortions created in the secondary lens        elements due to thermal cycling and thermal degradation due to        the higher operational temperatures

In addition, by providing LED modules which have higher operatingtemperatures due to the stability of optical grade silicone at suchtemperatures, it is possible to operate the LED modules at these highertemperatures in luminaires. This means that the luminaires can beoperated at higher currents to provide more luminous flux in the sameluminaire housing (as is the case for existing designs), or, for a givenluminous flux, the required heat dissipation capacity can be reducedwith an accompanying material cost saving (as would be the case for newdesigns).

Although the present invention has been described above with respect toparticular embodiments, it will readily be appreciated that otherembodiments are also possible.

While illustrative embodiments have been illustrated and described, itwill be appreciated that various changes can be made therein withoutdeparting from the spirit and scope of the invention.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A light-emitting diodemodule comprising: a printed circuit board having a first surface and asecond surface; a light-emitting diode array mounted on first surface ofthe printed circuit board, the printed circuit board being configured toprovide electrical connections to each light-emitting diode element inthe light-emitting diode array; a secondary lens array configured to bepositioned over the light-emitting diode array, the secondary lens arrayincluding a secondary lens element for each light-emitting diode elementin the light-emitting diode array; and a lens holder configured to bemountable to the printed circuit board and configured to retain eachsecondary lens element of the secondary lens array in alignment in anx-y plane with respect to each light-emitting diode element of thelight-emitting diode array; wherein the printed circuit board comprisesa first locating feature corresponding to a second locating feature onone of: the secondary lens array and the lens holder, the locatingfeatures providing the alignment of the secondary lens array withrespect to the light-emitting diode array on the printed circuit board.2. The module according to claim 1, wherein the lens holder isconfigured to maintain the secondary lens array at a predetermineddistance, in a direction perpendicular to the x-y plane, from the firstsurface of the printed circuit board.
 3. The module according to claim1, wherein the secondary lens array comprises a free form lens arrayhaving a first surface and a second surface located on opposite sidesthereof, the secondary lens elements being formed as a convex surface inthe first surface and as a concave surface in the second surface,respectively, of the free form lens array.
 4. The module according toclaim 3, wherein the lens holder comprises a frame operable to securethe free form lens array to the printed circuit board, the frame havinga first surface and a second surface which are located on opposite sidesthereof with apertures formed therethrough for receiving respective onesof the secondary lens elements.
 5. The module according to claim 4,wherein the frame includes at least one hole for receiving at least onepin formed in the first surface of the free form lens array, the firstsurface of the free form lens array being aligned with a second surfaceof the lens holder so that each pin extends through an associated hole.6. The module according to claim 3, wherein the secondary lens array ispositioned between the first surface of the printed circuit board andthe second surface of the lens holder.
 7. The module according to claim3, wherein the second surface of the free form lens array furthercomprises at least one positioning pin for engaging a correspondingrecess formed in the printed circuit board.
 8. The module according toclaim 7, wherein the second surface of the free form lens arraycomprises two positioning pins, each positioning pin having a differentcross-section.
 9. The module according to claim 3, wherein the lensholder further comprises an element for each secondary lens element ofthe free form lens array formed in the first surface of the lens arrayin the proximity of an associated aperture to prevent backlighting. 10.The module according to claim 1, wherein the secondary lens arraycomprises a collimator lens array including a plurality of collimatorlens elements.
 11. The module according to claim 10, wherein the lensholder comprises a frame operable to mount the collimator lens array tothe printed circuit board, the frame having a first surface and a secondsurface which are located on opposite sides thereof, the first surfacehaving a plurality of recesses defined therein, each recesscorresponding to a light-emitting diode of the light-emitting diodearray and being operable to receive an associated collimator lenselement.
 12. The module according to claim 10, wherein the lens holderincludes at least one positioning pin located on its second surface forengaging a corresponding aperture formed at least in the first surfaceof the printed circuit board.
 13. The module according to claim 12,wherein the lens holder includes two positioning pins each having across-section, and the first surface of the printed circuit board hastwo apertures each being shaped to receive a corresponding positioningpin.
 14. The module according to claim 11, wherein the lens holderfurther comprises at least one clip formed in an edge portion of eachrecess, each clip being operable to retain a collimator lens element inthe associated recess.
 15. The module according to claim 1, wherein thesecondary lens array comprises an optical grade silicone material. 16.The module according to claim 1, wherein the lens holder is configuredto provide alignment between the secondary lens array and the printedcircuit board in a direction perpendicular to the x-y plane.
 17. Themodule according to claim 1, wherein the lens holder is configured tomaintain the secondary lens elements at a predetermined distance fromthe light-emitting diode elements.
 18. The module according to claim 1,wherein the lens holder is configured to maintain a skirt portion of thesecondary lens array in contact with the printed circuit board.
 19. Aluminaire having a light-emitting diode module, the light-emitting diodemodule comprising: a printed circuit board having a first surface and asecond surface; a light-emitting diode array mounted on first surface ofthe printed circuit board, the printed circuit board being configured toprovide electrical connections to each light-emitting diode element inthe light-emitting diode array; a secondary lens array configured forbeing positioned over the light-emitting diode array, the secondary lensarray including a secondary lens element for each light-emitting diodeelement in the light-emitting diode array; and a lens holder configuredto be mountable to the printed circuit board and configured forretaining each secondary lens element of the secondary lens array inalignment in an x-y plane with respect to each light-emitting diodeelement of the light-emitting diode array; wherein the printed circuitboard comprises a first locating feature corresponding to a secondlocating feature formed on one of: secondary lens array and the lensholder for providing the alignment of the secondary lens array withrespect to the light-emitting diode array on the printed circuit board.20. A method of assembling a light-emitting diode module comprising aprinted circuit board having a first surface and a second surface, alight-emitting diode array mounted on the first surface of the printedcircuit board, a secondary lens array, and a lens holder having a firstsurface and a second surface, the method comprising: providing a firstlocating feature on the first surface of the printed circuit board;providing a second locating feature on one of: the secondary lens arrayand the second surface of the lens holder; forming a lens array assemblyby assembling the secondary lens array in the lens holder; and mountingthe lens array assembly on the first surface of the printed circuitboard with the first location feature cooperating with the secondlocating feature to align the secondary lens array with thelight-emitting diode array in an x-y plane.